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1. INTRODUCTION
Braking system is an energy converting system that converts vehicle movement into
heat while stopping the rotation of the wheels. This is done by causing friction at the
wheels.
There are two basic types of friction that explain how brake systems work: kinetic
or moving, and static or stationary. The amount of friction produced is proportional to
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Determination of Heat Transfer Coefficient of Brake Rotor Disc using CFD Simulation
the pressure applied between the two objects, the type of materials in contact & the
smoothness of their rubbing surfaces. Friction converts the kinetic energy into heat.
The greater the pressure applied to the objects, the more friction & heat produced, &
the sooner the vehicle is brought to a stop [1].
Belhocine Ali and Bouchetara Mostefa (2013) [3], analyzed the thermo
mechanical behavior of the dry contact between the brake disc and pads during the
braking phase. The thermal-structural analyze is then used to determine the
deformation and the Von Mises stress established in the disc, the contact pressure
distribution in pads.
D. Murali Mohan Rao, Dr. C. L. V. R. S. V. Prasad, T. Ramakrishna (2013) [4],
studied that the frictional heat generated during braking application can cause
numerous negative effects on the brake assembly such as brake fade, premature wear,
thermal cracks and Disc Thickness Variation (DTV). He stated that numerical
simulation for the coupled transient thermal field and stress field is carried out
sequentially by thermal-structural coupled method based on ANSYS to evaluate the
stress fields and of deformations which are established in the disc which is another
significant. He compared the results obtained by the simulation with those of the
specialized literature.
Behnam Ghadimi, Fars Kowsary and M.Khorami (2012) [5], investigated the
thermal analysis of the wheel-mounted brake disc R920K for the ER24PC
locomotive. The brake disc and uid zone were simulated as a 3D model with a
thermal coupling boundary condition. The braking process was simulated in
laboratory and the experimental data was used to verify the simulation results. During
the braking, he observed that the maximum temperature is in the middle of braking
process instead of the braking end point. Moreover, a large lagging was observed for
ns temperature which renders no cooling at the beginning of the braking
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necessary. Hence, the braking force on single wheel is directly proportional to the
dynamic weight transfer and the total braking force divided by two since in a four
wheel vehicle there are two discs each at the front wheels [1].
Where Am and Aw are area of master cylinder and caliper cylinders respectively,
Parameter
Value
220 kg
0.65
19 mm
28 mm
300N
Parameter
Value
1510.74 N
283.5 mm2
981.7 mm2
41.88mm
491 N
Further, it is necessary to determine and decide the inner and outer diameter of the
rotor disc. The inner and outer diameter of the rotor disc depends on the minimum
swept area required for applying brakes and the dimensions of the brake pad. It also
depends on the assembly constraints of the wheel assembly.
Considering the case of a vehicle having following assembly specifications:
Diameter of the wheel = 22
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Determination of Heat Transfer Coefficient of Brake Rotor Disc using CFD Simulation
For the above specifications and calculated values the rotor dimensions selected
are as follows.
Outer diameter of disc (Do) = 160 mm
Inner diameter of disc (Di) = 110 mm
Wbraked = 491/0.4
Wbraked = 1227.5 N
As the force is exerted by both the brake pads,
Wbraked = 2455 N
Parameter
Value
Density
7.845 g/cc
Tensile Strength
1475 MPa
Yield Strength
1005 MPa
Thermal Conductivity
24.9 W/ m-K
9.9 m/m/C
460 J/ Kg-k
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= Density of Material.
v = velocity of air
When Re > 2.4 * 105 the convective heat transfer coefficient h is of the form,
Ka = Thermal conductivity of air
Do = Outer diameter of disc
Preprocessing
Solver
Post-Processing
Geometric modeling
Grid Generation
Initial Condition and Boundary
Condition
Selection of Flow models
Contour Plots
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Determination of Heat Transfer Coefficient of Brake Rotor Disc using CFD Simulation
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q = 36504 W/m2
Inlet velocity (v) = 8.33 m/s
Heat flux into disc surface = 36504 W/m2
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Determination of Heat Transfer Coefficient of Brake Rotor Disc using CFD Simulation
182 W/m2K
187 W/m2K
187 W/m2K
234 W/m2K
The above results show that with the provision of grooves improves the heat
transfer coefficient at the vicinity of the grooves. Hence, further increasing the
number of the grooves enhances the heat dissipation rate. Further, provision of petals
over the outer edge of the disc increase the surface area as well improves the heat
transfer coefficient.
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5. CONCLUSION
The following comments could be concluded:1. CFD simulation provides an insight to flow physics at vicinity at effect of the grooves
on the heat transfer coefficient
2. Due to provision of grooves there is considerable increase in heat transfer coefficient
at vicinity of grooves, increased heat transfer coefficient increases the heat dissipation
rate.
3. The analytical solution of heat transfer coefficient and Numerical Solution are Close,
the difference in the values is due to provision of grooves which is not taken into
consideration while analytical calculation.
REFERENCES
[1]
[2]
[3]
[4]
[5]
[6]
[8]
Hardik D. Rathod, Ashish J. Modi and Prof. (Dr.) Pravin P. Rathod, Effect
of Different Variables on Heat Transfer Rate of Four-Stroke Si Engine
Fins - Review Study. International Journal of Mechanical Engineering and
Technology, 4(2), 2013, pp. 328333.
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